Fan control device for a heating or cooling system

ABSTRACT

A fan controller device runs the cooling and heating system fan in between cycles, thus maintaining all rooms of a building at a more even temperature. The fan controller device includes a plurality of sensors, a timing controller device operatively connected to the plurality of sensors, and a fan relay device operatively connected to the timing controller device. The fan controller device is adapted to be connected to a thermostat on a heating and air conditioning system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application No. 61/409,240 filed Nov. 2, 2010, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to a fan controller device for a heating or cooling system. More particularly, the present invention relates to a fan controller device that controls the operation of a fan based on the information received by sensors.

Existing heating and cooling systems use a thermostat to measure temperature. The thermostats are normally installed in a centrally located area in the building. When the system is not actively heating or cooling the building, the temperature of different rooms may vary, resulting in discomfort for the occupants. Unfortunately, the occupants may react to the change in temperature by lowering the thermostat setting or turning on a fan. Both of these options increase the use of energy. Some current heating and cooling systems may have a recirculating mode besides the normal fan AUTO and ON modes. These systems do operate the system fan in between heating and cooling operation but do not have the flexibility to adjust automatically to different environmental situations.

As can be seen, there is a need for a device that helps provide even temperatures in all rooms of a building without increasing the use of energy. In addition, there is a need for a device that operates the heating and cooling system fan in between operation, having the ability to adjust automatically to different temperature situations.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a fan controller device includes a plurality of sensors, a timing controller device operatively connected to the plurality of sensors, and a fan relay device operatively connected to the timing controller device.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a block diagram of a fan controller device according to an exemplary embodiment of the present invention showing the fan controller device wired to a heating and air conditioning system (NC system) and thermostat;

FIG. 2 illustrates an electrical schematic diagram of the fan controller device of FIG. 1 showing details of a bulk power supply device, a fan sensor, a heat sensor, an air conditioning sensor (AC sensor), on/off switch, and an input/output interface according to an exemplary embodiment of the present invention;

FIG. 3 illustrates another electrical schematic diagram of the fan controller device of FIG. 1 showing details of a 12 volt power supply device and a 3.3 volt power supply device according to an exemplary embodiment of the present invention;

FIG. 4 illustrates another electrical schematic diagram of the fan controller device of FIG. 1 showing details of a timer controller device and a fan relay according to an exemplary embodiment of the present invention; and

FIG. 5 illustrates a block diagram of the fan controller device of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Various inventive features are described below that can each be used independently of one another or in combination with other features.

Broadly, embodiments of the present invention generally provide a fan controller device that runs the cooling and heating system fan in between cycles. Thus, all rooms in the building are maintained at a more even temperature.

The fan controller device according to the present invention may monitor different parameters such as the operation of the heating system, cooling system, or fan system, and adjust the fan system cycles toward an optimum frequency and duration so the occupants will be at a comfortable level regardless of their location in the building. The fan controller device may be used as part of a buildings HVAC system or part of a home's system.

FIGS. 1-5 illustrate a fan controller device 10 according to an exemplary embodiment of the present invention. The fan controller device 10 may be connected to an existing heating and A/C system 12 and a thermostat 34. The fan controller device 10 may include a bulk power supply device 14, a 12 volts power supply device 16, a 3.3 volt supply 17, a fan relay 18, a fan sensor 20, a heat sensor 22, an air conditioning sensor 24, an on/off switch 30, and an input/output interface 28.

The bulk power supply device 14 may receive voltage from a commercially available power supply device. The bulk power supply device 14 may include a fuse 14 a, a bridge rectifier 14 b, and a capacitor 14 c. A 24 volt alternate current device (24 VAC) (not shown) located on the cooling and heating system 12 may be connected to the bulk power supply device 14 as shown in FIG. 1. The bulk power supply device 14 may rectify the voltage received from the 24 VAC device (not shown) and produce a direct current voltage (DC voltage) of about 34 volts. The 34 volt DC voltage may be stored on the capacitor 14 c used by the 12 volt power supply device 16 to make a DC voltage of 12 volts.

The 12 volt power supply device 16 may be a commercially available 12 volt power supply device. The 12 volt power supply device 16 may include a linear voltage regulator 16 a, capacitors 16 b, and resistors 16 c. The 12 Volt power supply device 16 may receive an input voltage from the bulk power supply device 14 and create a voltage to control the switching of the fan relay 18 and an input voltage to power a 3.3 Volt supply device 17.

The 3.3 Volt power supply device 17 may be a commercially available 3.3 Volt power supply device. The 3.3 Volt power supply device 17 may include a buck converter chip 17 a and associated capacitors 17 b, diodes 17 c, resistors 17 d, and inductor 17 e. The 3.3 Volt power supply device 17 may receive its input voltage from the 12 Volt power supply device 16 and may produce 3.3 volts. The 3.3 Volt power supply device 17 may provide voltage to power a timing controller device 26.

The timing controller device 26 may be a commercially available timing controller device. The timing controller device 26 may include a microcontroller 26 a, a transistor 26 b, a programming connector 26 c, and associated jumpers 26 d, resistors 26 e, capacitors 26 f, and LEDs 26 g. The operation of the timing controller device 26 may be controlled by a program entered through the programming connector 26 c. The program may be designed to respond to varying environmental and heating and cooling situations. The timing controller device 26 may be programmed to receive information from sensors 32 and may determine the best interval and duration to turn on the system fan for optimum comfort.

Sensors 32 may be used to gather information about the operation of the heating and air conditioning system and/or the environment. These signals may be sent to a timing controller device 26 for evaluation. The sensors 32 may be commercially available sensors. In some embodiments, the sensors 32 may include a fan sensor 20, a heat sensor 22, and an AC sensor 24. Each sensor 32 may include a bridge rectifier 20 a, 22 a, 24 a; an optocoupler 20 b, 22 b, 24 b, and associated capacitors 20 c, 22 c, 24 c and resistors 20 d, 22 d, 24 d.

The heating and air conditioner control system 12 may provide a 24 VAC when fan system operation is required. This signal may be connected to the input/output interface device 28 and sent to the fan sensor 20. The fan sensor 20 may rectify the 24 VAC voltage and may turn on the light emitting diode (LED) of the optocoupler 20 b. The transistor of the optocoupler 20 b may provide a signal to the timing controller device 26 when the system fan may be operating.

The heating and air conditioner control system 12 may provide 24 VAC when heat operation is required. The signal may be connected to the input/output interface device 28 and sent to the heat sensor 22. The heat sensor 22 may rectify the 24 VAC voltage and may turn on the LED of the optocoupler 22 b. The transistor of the optocoupler 22 b may provide a signal for the timing controller device 26 when the heater may be operating.

The heating and air conditioner control system 12 may provide 24 VAC when AC operation is required. The signal may be connected to the input/output interface device 28 and sent to the AC sensor 24. The AC sensor 24 may rectify the 24 VAC voltage and may turn on the LED of an optocoupler 24 b. The transistor of the optocoupler 22 b may provide a signal for the timing controller device 26 when the AC may be operating.

The information gathered by the sensors 32 may be sent to the timing controller device 26. The timing controller device 26 may use the information from the sensors 32 and determine the optimum time to turn on the system fan. When the timing controller device 26 reaches a decision to turn on the system fan, the timing controller device 26 may send a signal to the fan relay 18. The fan relay 18 may then turn on the system fan as directed from the timing controller device 26.

The fan relay 18 may be a commercially available fan relay. In some embodiments, the fan relay 18 may be a single pole double throw relay. In addition, the fan relay 18 may allow the fan system to operate in the normal condition when the printed circuit board power (PCB power) may be turned off by the on/off switch 30. The fan relay 18 may be connected to the input/output interface device 28 for the system fan operation. The fan relay 18 may provide a signal to operate the system fan in two different ways. The first way may be directly. This is when the system heating or air conditioner turns on the system fan. When this happens a signal may be sent through the normally closed contact of the fan relay 18 and out to the input/output interface device 28 to operate the system fan. The second way the system fan is turned on may be when the fan relay 18 may be energized by the timing controller device 26. In this case, the timing controller device 26 may already determine that the system fan operation may be beneficial to the building or household temperature comfort level. The 24 VAC that may be connected to the normally open contact of the fan relay 18 is then sent to the input/output interface device 28 to operate the system fan.

Although there are many variations in heating and cooling controller systems 12, all generally provide five connections for the thermostat 34. A connection from the thermostat 34 to the input/output interface 28 may be needed in order for the fan controller device 10 to control the fan system.

The on/off switch 30 may be a commercially available on/off switch. In some embodiments, the on/off switch 30 may be a single pole double throw switch. The on/off switch 30 may energize or turn off the circuit. When in the off position, the on/off switch 30 may assure continuity between the fan sensor 20 and the fan relay 18 terminals on the input/output interface device 28.

The input/output interface device 28 may include the necessary connections to provide power to the fan controller device 10. In addition, the input/output Interface device 28 may provide connections for the sensors 32.

All of the components of the fan controller device 10 may be placed on a printed circuit board. A design draftsman may design the printed circuit board, then the design may be laid-out on the printed circuit board by a qualified worker, and finally the components may be assembled on the printed circuit board. The size of the circuit board may depend on the layout design. In some embodiments, the printed circuit board may be about two inches in height by three inches in width.

The fan controller device 10 may be incorporated inside a thermostat 34. This might be desirable since all the sensor signals used by the fan controller device 10 may be available at the thermostat 34. Many thermostats are programmable so the addition could be easily done.

In addition, the fan controller device 10 may be placed in the heating and air conditioner controller 12. All the signals used for the design may be available on the heating and air conditioner controller 12. Many controllers are programmable so the addition could be easily done.

In some embodiments, a computer (not shown) may be used to replace the microcontroller 26 a.

The installation of the fan controller device 10 may be made by a licensed heating, ventilation and air conditioner (HVAC) service personnel. Once the fan controller device 10 unit may be installed there are only a few things that a user needs to do to operate the fan controller device 10. The user may turn on the on/off switch 30 to start the operation of the fan controller device 10. The on/off switch 30 may be turned off to have the fan controller device 10 turned off.

A sleep mode may be included on the fan controller device 10. The sleep mode may be started when the air conditioner has not run for a predetermined time. If desired, the sleep mode may be stopped by turning the on/off switch 30 to the off position for 5 seconds and then turn it on again. Additionally, the fan controller device 10 may automatically come out of sleep mode if the air conditioner is operated.

These fan cycles created between heating and cooling cycles by the fan controller device 10 may be sufficient to balance the temperature throughout the building. In addition, the fan controller device 10 may use less energy and have less audible noise than running the fan system continually.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

1. A fan controller device comprising: a plurality of sensors; a timing controller device operatively connected to the plurality of sensors; and a fan relay device operatively connected to the timing controller device.
 2. The fan controller device according to claim 1, wherein the plurality of sensors include a fan sensor, a heat sensor, and an air conditioning sensor.
 3. The fan controller device according to claim 1, further comprising a power supply device, wherein the power supply device is operatively connected to a 24 volt alternate current device (24 VAC) located on a cooling and heating system.
 4. The fan controller device according to claim 1, wherein the timing controller device includes a microcontroller, a transistor, and a programming connector, wherein the timing controller device is programmed to receive information from sensors and determines when and how long to turn on a fan system on a heating and cooling system.
 5. The fan controller device according to claim 4, wherein the timing controller device is controlled by a program entered through the programming connector, wherein the program is designed to respond to varying environmental and heating and cooling situations.
 6. The fan controller device according to claim 2, wherein the fan sensor receives a signal from the air conditioner control system when a fan system operation is required, wherein the fan sensor provides a signal to the timing controller device to determine when a fan operation is required.
 7. The fan controller device according to claim 2, wherein the heat sensor receives a signal from the heating and air conditioner system when raising the temperature is required, wherein the heat sensor provides a signal to the timing controller device to determine when a fan operation is required.
 8. The fan controller device according to claim 2, wherein the air conditioner sensor receives a signal from the heating and air conditioner system when lowering the temperature is required, wherein the heat sensor provides a signal to the timing controller device to determine when a fan operation is required.
 9. The fan controller device according to claim 4, wherein the timing controller device sends a signal to the fan relay to turn on the fan system.
 10. The fan controller device according to claim 1, further including a printed circuit board to support the fan controller device.
 11. The fan controller device according to claim 1, further including an input/output interface device, wherein the input/output interface device includes a plurality of connections to provide power to the fan controller device.
 12. The fan controller device according to claim 1, wherein the fan controller device is incorporated inside a thermostat on a heating and air conditioning system.
 13. The fan controller device according to claim 1, wherein the fan controller device is incorporated inside a heating and air conditioned controller on the heating and air conditioning system.
 14. The fan controller device according to claim 1, further including a sleep mode, wherein the sleep mode starts after absence of activity for a predetermined time. 